HVACR Nation September 2017 by AIRAH

FEATURE

The R32 roll-out

Skills WORKSHOP

Frontline

Variable head-pressure control and variable inter-stage pressure control

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ISSUE 105

HVAC&R Nation is published by the Australian Institute of Refrigeration, Air conditioning and Heating (Inc).

September 2017

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Levelling the playing field

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Magazine team Managing Editor Matthew Dillon matt@airah.org.au Tel: 03 8623 3011 Assisant Editor Brihony Tulloch brihony.tulloch@airah.org.au Tel: 03 8623 3011 Contributing writer Sean McGowan

Advertising sales Glenn Douglas glenn@airah.org.au Ph: 03 8623 3018

Numerous studies have shown that diversity in the workplace can lead to a more successful business. Although the Australian HVAC&R industry is a great example of cultural diversity at work, we lag behind others when it comes to gender diversity. But as Sean McGowan reports, this is changing too.

John McGrath john@airah.org.au Ph: 03 8623 3007

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Skills Workshop

The Toolshed

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Variable head-pressure control and variable inter-stage pressure control.

8 Global Update industry news from around the world

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Disclaimer HVAC&R Nation is an official publication of the Australian Institute of Refrigeration, Air Conditioning and Heating Inc. Statements expressed in HVAC&R Nation do not necessarily reflect the policy or views of AIRAH or its members. No responsibility is accepted by AIRAH, the Editor or HVAC&R Nation’s supply partners for the accuracy of information or for errors or omissions. HVAC&R Nation is distributed without charge to all financial members of AIRAH. The publisher reserves the right to alter or omit any article or advertisement submitted and requires indemnity from advertisers and contributors against damages or liabilities that may arise from material published. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means electronic, mechanical, photocopying, recording or otherwise, without permission of the Publisher.

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The roll-out continues Despite the widespread adoption of R32 by most leading air conditioning manufacturers of splits and smaller systems, unfounded misgivings continue to exist at the industry’s grassroots level around flammability issues. Sean McGowan reports.

Please consider the environment and recycle this magazine if you are not going to keep it.

September 2017 | www.airah.org.au/nation | HVAC&R Nation | 3

Editorial

Everything you wanted to know about R32

BUT WERE AFRAID TO ASK This issue of HVAC&R Nation shines the spotlight on refrigerants and refrigeration. That probably doesn’t come as much of a surprise, because ever since its establishment 10 years ago, “the Nation” has celebrated, explored and explained everything to do with the “R” in HVAC&R. It was ever thus. It’s our thing. What you may not know is that AIRAH, the organisation that brings you this mag, was actually founded as the Victorian Institute of Refrigeration way back in 1920. For those of you who are good with figures, that was nigh on 100 years ago. And the Institute has been putting out material dedicated to improving knowledge and awareness around refrigeration for 70 years! The Journal of Refrigeration was first published in July 1947. In that first issue, the esteemed Joseph Raymond from the London-based Institute of Refrigeration wrote how unfortunate it was that it took the devastating Second World War to highlight the value of refrigeration.

Without refrigeration, Raymond wrote, it would have been impossible for soldiers operating in far-off destinations to be kept well fed, or supplied with fresh blood transfusions when these were needed. All these many years later, and there’s no need to preach the importance of refrigeration to anybody, really, but especially for a publication aimed at fridgies. These days the HVAC&R industry continues to evolve in response to society’s values and government legislation, particularly around environmental issues.

In order to have a lower GWP, a refrigerant’s chemical compounds are typically less stable, and therefore more flammable. That’s how it works. With R32 there has been some confusion since it was first introduced here in splits and smaller systems in 2014. Despite assurances from AREMA and others that everything is as it should be, confusion remains. That’s where HVAC&R Nation can help. You have questions about R32. We have answers.

For instance, since the introduction of the Montreal Protocol and the phase-out of HCFCs began, the RAC industry has driven the development of a range of synthetic refrigerants with low global warming potential (GWP). One of these is R32. Here’s the thing: there’s always been a trade-off between GWP and flammability which has to do with the physical characteristics of chemicals.

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Matthew Dillon Managing Editor matt@airah.org.au

Want to connect with AIRAH? There are lots of ways to stay up to date with what we’re doing.

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4 | HVAC&R Nation | www.airah.org.au/nation | September 2017

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September 2017 | www.airah.org.au/nation | HVAC&R Nation | 5

Toolshed 01

“To complement its attractive design, the Aero Series provides comfort and peace of mind with controlled airflow, purified healthy air, and smart energy savings.”

If the Jacket fits

The Yellow Jacket trancritical CO2 manifold, gauge and hose set is specifically engineered for the service, vacuum and charging of 120bar trancritical systems.

The range includes both reverse-cycle and cooling-only models. “The Aerowing’s blades … provide ‘shower cooling’, which directs cool air across the ceiling to shower down naturally, spreading over a wider area of a room and minimising any uncomfortable direct airflow chill,” Panasonic says. “When ‘fast cooling’ is required, the blades direct airflow downwards, delivering concentrated cool air the moment the air conditioner is switched on.”

Made from high-strength forged aluminium with the Yellow jacket double o-ring piston, the set has new fine-pitch threads to allow for finer adjustment. The vacuum/charging ports are now enlarged with 3/8 connections and appropriate 1.8m hoses fitted. They are now available from all leading wholesalers.

Go to www.panasonic.com.au n

The Yellow Jacket Australian representative is Sky Refrigeration. Ph: (03) 9735 2313. Go to www.yellowjacket.com n

Apac at the ready

Toshiba has a new, apartment-ready Single-Fan MiNi VRF. “We all know that there is a continuing boom in apartment developments right around the country,” says John Caione, Toshiba’s business unit manager for residential and light commercial products. “This is where the Toshiba Single Fan MiNi VRF comes to the rescue. Our inspiration for this product was sourced from the end consumer’s desire for an apartment that has style and plenty of balcony room.”

Apac is a new packaged refrigeration condensing unit range from Actrol. Designed by Tecumseh, the series includes models with hermetic, scroll and semi-hermetic compressors. Eight models are now available, with refrigeration capacities from 4.6kW to 33.6kW at medium temperature, and 0.99kW and 8.3kW at low temperature.

Toshiba air conditioning’s technology is on show, with the product connecting up to five indoor units and including a 210mm (H) & 450mm (D) super-slim ducted outlet boasting a low-noise fan. “Toshiba’s remarkable twin-rotary inverter compressor with generous energy efficiency delivers stable performance with minimal friction,” says the firm, “making this an ideal team for the ultimate in design flexibility and noise-sensitive applications.” n

Actrol says the APS range is fully fitted, wired, and protected, making it easy to apply to many cooling and freezing applications such as supermarkets, fast-food outlets, restaurants, food processors, butchers, florists, and other applications. The APS semi-hermetic range has also been extended with the inclusion of more Tecumseh semi-hermetic compressors for both medium- and low-temperature applications. Go to www.accutrolllc.com n

Plug and play from HFT

06 03

Designed with maximum comfort and energy efficiency in mind, Climaveneta can be used in IT cooling in modern and mixed-use buildings such as shopping centres, large business centres, hotels, swimming pools, data centres and wellness centres.

HFT says the plugs have a variety of other applications for sewage and drainage systems, ducting and conduit, as well as swimming pools. HFT says the plugs can also be used to seal and protect tanks, vessels and containers during cleaning and transportation, particularly when they are pressurised with inert gas. 04

Other plugs and stoppers in the division include mechanical plugs for low-, medium- and high-pressure stopping requirements, and inflatable stoppers.

Panasonic’s Aero hero

The latest addition to Panasonic’s new range is its Aero series. “The Aero series features a new slim design and is narrower in depth, projecting less from the wall to blend more subtly with home interiors,” Panasonic says. “This new styling has seen

6 | HVAC&R Nation | www.airah.org.au/nation | September 2017

“Known as ‘Integra’, the four-pipe system used by Climaveneta is suitable for buildings that require separate areas to be cooled and heated at the same time,” the company says. “Combined with centralised solutions, Integra allows for production of cold and hot water in two hydronic circuits of the system, ensuring maximum comfort in every room of the building, independently all year around. “Available in ranges of 33kW to 1125kW, the Integra range provides flexible equipment selection, with the ability to select from components and features such as full inverter screw compressors, scroll compressors, EC fans, HFO refrigerant compatibility for screw compressors and +2P modules, which is an integrated module for independent production of hot water of up to 78°C.”

Go to www.huntingdonfusion.com n

Panasonic receive an IF Design Award in Europe. The unit features an elegant gloss white finish and gently rounded horizontal panel with two tapered sides.

Climaveneta cooling

Earlier this year Mitsubishi Electric Australia announced it had secured the right to sell Climaveneta-branded chillers in Australia.

The Pipestoppers division at Huntingdon Fusion Techniques (HFT) manufactures a range of heavy-duty aluminium plugs designed to withstand exposure to high temperatures and immersion in chemicals. The plugs are available in sizes from 38mm– 900mm.

Toshiba’s MiNi VRF

The Climaveneta Integra system has been used in more than 1,000 projects worldwide. In Australia, the Integra has been installed at projects such as the Gold Coast’s Sheraton Mirage Resort, the Royal Institute For Deaf and Blind Children in Sydney, and the Canberra North Building. Go to www.MitsubishiElectric.com.au n

Toolshed 07

“Conex Bänninger is an ISO 9001 quality-assured company,” the firm says, “which ensures you receive the very best in quality.”

The MaxiPro way

MaxiPro is a copper-press system suitable for air conditioning and refrigeration applications.

Go to www.connexbanninger.com.au n 06

“Benefiting from over 100 years’ experience in fittings manufacture and over two decades experience in press system design, MaxiPro is set to revolutionise pipe jointing in air conditioning and refrigeration applications,” the firm says. “MaxiPro is a robust press system, which is quick and simple to use, providing a secure and permanent joint.

The BEST around

Bitzer has introduced the latest update for its Electronics Service Tool – BEST software – which allows refrigeration and service engineers to operate all Bitzer IQ products from their computers.

“Compared with traditional techniques, it significantly improves productivity through greatly reduced installation time and enhanced working flexibility. MaxiPro can be used with hard, half-hard or annealed copper tube conforming to EN 127351 or ASTM-B280, in both air conditioning and refrigeration applications.”

MaxiPro is approved for use with R1234yf, R1234ze, R32, R134a, R404A, R407C, R407F, R410A and R507. “Partnering early on with the client at design stage, working with cutting-edge technologies such as MaxiPro allow us to deliver certainty of buildability and meet program deadlines in a safe and economic way,” says Ventrix Pty Ltd owner Andrew Markopoulos.

“The BEST software provides users with a comprehensive overview of the operating status, configuration and troubleshooting of Bitzer compressors, frequency inverters and condensing units,” Bitzer says. “BEST makes it much easier for service engineers to do their work, as it allows them to quickly and safely adjust device parameters, analyse errors, display data logs, update the firmware, and more. Bitzer has updated the tool for commissioning, monitoring and servicing compressors and their electronic components, now available in version 2.8.” The new features include a more extensive range of data log functions for device logs, including the ability to display counters and statistics as well as an alarm message table.

The MaxiPro range is distributed by Conex Bänninger, a specialist in providing fittings, valves and accessories since 1909.

DO YOU HAVE A NEW PRODUCT TO GO IN THE TOOLSHED?

Go to www.bitzer.com.au n

Email brihony.tulloch@airah.org.au All submissions received will be considered, though publication cannot be guaranteed.

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September 2017 | www.airah.org.au/nation | HVAC&R Nation | 7 HVAC HP Be Impressed 220X150 NoBleed v1.indd 1

19/10/2015 12:23 pm

Global Update

GERMANY

DAIMLER’S CO2 JOURNEY Sanden Automotive Components has started the supply of compressors for CO2 air conditioning to Daimler. In accordance with these environmental policies, the European directive on mobile air conditioning systems (MACs), introduced a ban for the use of refrigerant gas with a global-warming potential (GWP) higher than 150, applicable for all new cars sold in the European Union since January 1 this year. “Daimler chose Sanden for the development of the R744 compressor because of their extensive experience with this refrigerant and pioneering spirit towards new technologies,” says Daimler project leader R744, Ralf Theurer.

CHINA

PANDA POWER! A new 100-hectare solar power plant in Datong, China, has been built in the shape of a giant panda. The first phase, which includes one 50mW plant, delivers power to a grid in north-western China, and a second panda is planned for later this year. Called the Panda Power Plant, it will be able to produce 3.2 billion kW/h of solar energy, according to the company. That will eliminate approximately million tonnes of coal that would have been used to produce electricity, reducing carbon emissions by 2.74 million tonnes. “Designing the plant in the shape of a panda could inspire young people and get them interested in the applications of solar power,” says Panda Green Energy CEO Li Yuan.

“It has been quite a challenging project also for Daimler to get the R744 AC system launched in such a short period. Therefore, the strategic partnership with Sanden has been very important, and we are pleased about this successful launch.” n

China Merchants New Energy Group worked with the United Nations Development Program (UNDP) to make the Panda Power Plant a reality.

USA

BELGIUM

There are also plans to bring Panda Green Power to Fiji and the Philippines. n

QATAR

THROWING IN THE TOWEL Workers working onsite in Qatar in the lead up to the 2022 soccer World Cup will make use of special cooling towels to combat the sweltering heat. The towels have the capability to cool core temperatures for up to four hours after being submerged in water. And 9,400 of them will be provided for workers across World Cup construction sites. So far, about 1,000 workers at Al Wakrah Stadium are already making use of the towels, wearing them on their necks, arms or in their pockets to receive the cooling effect without restricting movement. Another pilot program at Al Wakrah Stadium involving a lightweight evaporative cooling vest is also being developed. In December, cooled helmets were designed, developed and tested. n

NORWAY

NATURAL SHIFT

RENEGADE R22

GAS BE GONE

The Pilot Natural Refrigerant Incentive Program being offered by electricity supplier Sacramento Municipal Utility District (SMUD) is thought to be a first-of-its-kind scheme to help businesses shift to low-GWP refrigerants ammonia, CO2, or hydrocarbon.

R22 refrigerant was found along with cocaine and cigarettes in a haul of illegal items seized in a large-scale operation targeting counterfeit goods in Belgium.

The largest producer of oil and natural gas outside of the Middle East, Norway, is set to become the first country in the world to ban the use of gas to heat buildings.

The European Anti-Fraud Office (OLAF) executed Operation Renegade, which primarily targeted the international trade in counterfeit auto spare parts. However, the operation has also managed to seize an additional 400,000 counterfeit goods, including chewing gum, toys, perfumes, headphones, garden appliances and sunglasses.

Government officials will reportedly pass legislation to stop the use of oil and paraffin to heat buildings beginning in 2020.

Local businesses in Sacramento, such as grocery stores and food processors, will be eligible to receive grants of up to US$150,000 (AU$190,000) when upgrading equipment or selecting equipment for new facilities. “This new incentive will help reduce local greenhouse gas emissions and help develop and promote new refrigerant technologies that can provide a number of benefits to our customers and our community,” says SMUD CEO Nicole Howard. n

A total of 8,024kg of R22 has been seized so far. The R22 seizure was found in two shipments – one of 490 cylinders and the other of 100 cylinders. The origin of the refrigerants is unclear, but preliminary investigations suggest they were transhipped in Afghanistan then transported to Pakistan. n

8 | HVAC&R Nation | www.airah.org.au/nation | September 2017

Norway’s Ministry of Climate and Environment says the ban will encompass new and existing private homes, public spaces of businesses, and state-owned facilities. The plans are expected to lessen Norway's emissions of heat-trapping greenhouse gases by an estimated 340,000 tonnes per year. n

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September 2017 | www.airah.org.au/nation | HVAC&R Nation | 9

Feature

THE ROLL-OUT CONTINUES

Despite the widespread adoption of air condition R32 by most ing manufac leading turers of spli misgivings c ts and small ontinue to e er systems, xist at the in dustry’s gras flammability sroots level a issues. Sean round McGowan reports. Since the introduction of the Montreal Protocol, and the phase-out of HCFCs, the refrigeration and air conditioning industry has driven the development of a range of synthetic refrigerants with low global warming potential (GWP). R32 was among the new lower-GWP refrigerants to emerge, but the regulations and standards in place at the time largely disqualified it from use due to its flammable properties placing it in the A2 (now A2L) classification. Rather, it was blended with other refrigerants to create a safer option – albeit at the cost of a higher GWP. For example, R410A – commonly found in packaged and split systems – is a blend of R32 and the fire suppressant R125. Another refrigerant blend, R407C, contains 23 per cent R32. The trade-off between GWP and flammability has always existed around refrigerants due to the physical characteristics of chemicals. To have a lower GWP, the refrigerant’s chemical compounds are typically less stable and therefore more flammable. Conversely, to achieve more stability and reduce flammability in the refrigerant, the GWP increases.

FORGING AHEAD In Australia, AS/NZS 817:2016 classifies the flammability of refrigerants into four categories: not flammable (Class 1), lower flammability (Class 2L), flammable (Class 2) and higher flammability (Class 3). Under this standard, any refrigerant and air mixture that is capable of self-propagating a flame falls into one of the three flammable categories. Class 2L (or A2L) refrigerants present the lowest risk of the three flammable categories, and are defined as exhibiting very slight flammability. Being poor fuels, their burning velocity is under 10cm per second. “They require large leaks to become flammable, and have a very slow burn velocity,” says A-Gas Australia commercial manager Graeme Dewerson, Affil. AIRAH. “These gases are very unlikely to explode.” Balancing the industry’s need to adopt lower-GWP refrigerants against the low risk of flammability has led to most leading air conditioning manufacturers of splits and smaller systems embracing R32.

10 | HVAC&R Nation | www.airah.org.au/nation | September 2017

R32 ACROSS THE GLOBE Following the introduction of the first R32 units in Japan in 2012, all major Japanese manufacturers soon adopted the refrigerant. R32 units were then introduced into India in 2013, with Australian and Asian countries following suit in 2014. Such is the take up that Daikin estimates more than 27 million R32 units have been sold in more than 50 countries worldwide as of the end of March 2017. In contrast, the uptake of R32 in the US has been limited due to the country’s building codes, which do not permit the use of flammable refrigerants. Despite the US falling out of step with most of the world, Donald Prather, technical services manager for Air Conditioning Contractors of America (ACCA) believes there is a future for R32 – even as new low-GWP hydrofluoroolefin (HFO) options emerge in the market. “It looks like the next generation of replacement refrigerants will come from new HFO blends, and once US codes are updated – R32,” says Prather. “My best guess is that common sense will prevail, the industry will work to get our existing codes to approve the use of R32, and it will become the refrigerant of choice over the more expensive HFO blends.”

QUESTIONS REMAIN Although the uptake of R32 has been strong among original equipment manufacturers (OEMs), concerns around the flammability and toxicity of R32 have denied it a smooth entry into the Australian marketplace.

Feature This likely stems from confusion as to the flammability and toxicity of the refrigerant when it was first introduced in splits and smaller systems across Australia in 2014. Those who had concerns pointed to Material Safety Data Sheets (MSDS), which described the potential hazards. In response, the Australian Airconditioning and Refrigeration Equipment Manufacturers’ Association of Australia (AREMA) and the Consumer Electronics Supplier Association (CESA) released a technical fact sheet aimed at allaying such fears. “Research conducted to prepare the document confirms that R32 is not an extremely flammable, highly toxic gas that causes cancer, as some industry representatives have suggested,” AREMA said at the time of the fact sheet’s release. Equipment manufacturers, including Daikin, also invested significantly in industry training when launching R32 into the local industry. But three years on, concerns remain.

Flammability Classification under AS/NZS 817:2016 Class 1

(Not Flammable)

Class 2L

(Lower Flammability)

Class 2

(Flammable)

Flammability Criteria (AS/NZS 817:2016

• Does not exhibit flame propagation

Class 1 refrigerants do not burn at the pressure and temperature conditions used for testing (60°C)

R134a R404A R449A R744

• Exhibits flame propagation • Lower flammability limit of >3.5% by volume • Heat of combustion of <19,000 kj/kg • Burning velocity of <10cm

Class A2L refrigerants exhibit very slight flammability. They are poor fuels, require large leaks to become flammable and have a very slow burn velocity. These gases are very unlikely to explode.

R32 R1234yf R717

• Exhibits flame propagation • Lower flammability limit of >3.5% by volume • Heat of combustion of <19,000 kj/kg

Class 2 refrigerants are flammable, they tend to be poor fuels but have faster burning velocities and are therefore more likely to explode.

R152a

• Exhibits flame propagation • Lower flammability limit of <3.5% by volume

Class 3 refrigerants are highly flammable. These gases are used as fuels and produce large amounts of heat when they burn. They only require a small leak to form a flammable mixture and are likely to cause explosions due to high burning velocity.

R290 R600a R1270

According to Dewerson, his discussions with contractors around the country have revealed that a “fear factor” still exists around R32. “Contractors hear the word flammable and don’t necessarily hear or understand the meaning of ‘mildly’ or ‘highly’ before it,” he says.

Class 3

(Higher Flammability)

Refrigerant Examples

Description

But as the table clearly demonstrates, R32 falls into a category that is very much at the lower end of flammability.

Source: A-Gas

Hydrocarbon Refrigerants Technical support and application engineering advice available for the safe use and correct application of all Engas products.

1300 463 642

Engas M10 Suitable for replacement of all R600a refrigerators and freezers.

Engas M40 Pure hydrocarbon refrigerant replacement R290 and R22.

www.engas.com.au

Engas M20 Special purpose hydrocarbon refrigerant specifically designed to replace R32.

Engas M50 Suitable replacement for R22, R502, R404a, R407c and R507c.

Engas M30 Designed as a direct replacement for R12 and R134a.

Engas M60 Special purpose hydrocarbon refrigerant specifically designed to replace 410a.

September 2017 | www.airah.org.au/nation | HVAC&R Nation | 11

Feature OZONE? OH NO!

FAQs What is ozone depletion potential (ODP)?

Research recently released in the UK predicts that the healing of the Earth’s ozone layer could be delayed by as much as 30 years due to the increasing emissions of dichloromethane – also known as methylene chloride. Dichloromethane is a solvent used in a variety of industries and applications – including in the production of R32 (difluoromethane).

The ozone layer is damaged by the catalytic action of chlorine and bromine in compounds, which reduce ozone to oxygen when exposed to UV light at low temperatures. The ozone depletion potential (ODP) of a compound is shown as an R11 equivalent (ODP of R11 = 1).

What is global warming potential (GWP)? R410A – commonly found in packaged and split systems – is a blend of R32 and the fire suppressant R125.

Researchers point to recent growth in dichloromethane emissions as contributing to an increase in the level of chlorine present in the lower atmosphere.

And as the AREMA fact sheet pointed out, the characteristics of R32 make even intentional ignition difficult.

Although dichloromethane has a short lifespan of just a few months in the atmosphere, as it breaks down it releases chlorine, which can destroy ozone if it reaches the stratospheric ozone layer.

“If an accidental release of R32 refrigerant occurs from a cylinder or piping, the velocity will be too high to ignite near the release point and the concentration will be too low where the velocity becomes low enough,” stated AREMA in their R32 fact sheet.

Dr Ryan Hossaini, a geoscientist at Lancaster University in the UK, believes that by 2050, dichloromethane could account for a quarter of all the chlorine in the lower atmosphere.

“So, ignition of R32 is difficult, even if it is attempted intentionally.”

Source: nature.com

The greenhouse effect arises from the capacity of materials in the atmosphere to reflect the heat emitted by the Earth back onto the Earth. The direct global warming Potential (GWP) of a compound is shown as a CO2 equivalent (GWP of a CO2 molecule = 1).

Boasting a GWP of 675, R32 compares favourably to those refrigerants it replaces such as R410A (GWP of 2088) and R22 (GWP of 1810) – even if it is considered to have a “lower” rather than “low” global warming potential. “Reduced-GWP HFCs – like R32 – are readily a vailable, and a good way to reduce carbon footprint,” says Dewerson.

From an environmental standpoint, it must be acknowledged that lower-GWP refrigerants such as R32 have a key role to play as the industry phases out HFCs and transitions to the next generation of lowGWP refrigerants such as HFOs and naturals.

“The growth of R32 in air conditioning equipment at the expense of R410A is an excellent example of the

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Feature

REFRIGERANT PHASE-OUT TIMELINE

The characteristics of R32 make even intentional ignition difficult

industry following this trend. And despite the higher pressures and mild flammability associated with it, it is a good example of the industry overcoming the technical challenges of the refrigerant to release safe equipment with far less environmental impact than the current, mainstream alternative.â&#x20AC;?â&#x20AC;&#x201A; n

1987

Montreal Protocol established to address the depletion of the ozone layer by harmful substances with an ozone-depleting potential (ODP).

1989

Montreal Protocol comes into force

1990

Halon and CFC phase-outs agreed under Montreal Protocol

1992

Amendment to Montreal Protocol to schedule phase-out of HCFCs

1993

Importation of Halons phased out in Australia

1996

Importation of CFCs phased out in Australia

1996

HCFC phase-out commences in Australia

1997

Kyoto Protocol established to reduce human-induced greenhouse gases (GHGs) in an effort to address climate change.

2007

Australia ratifies signatory to Kyoto Protocol

2009

HFC phase-down discussions commence under Montreal Protocol

2016

Importation of HCFCs phased out in Australia

2016

HFC phase-down agreed under Montreal Protocol (Kigali Amendment)

2018

HFC phase-down to commence in Australia from January 1, 2018

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September 2017 | www.airah.org.au/nation | HVAC&R Nation | 13

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14 | HVAC&R Nation | www.airah.org.au/nation | September 2017

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Skills summary n What? A guide to help understand and manage energy-saving opportunities associated with industrial refrigeration variable head-pressure control and variable inter-stage pressure control.

n Who?

Variable head-pressure control and variable inter-stage pressure control (VIPC) are strategies which aim to improve a plant’s energy efficiency by optimising both the head pressure and the intermediate-stage (inter-stage) pressure of the refrigeration plant, based on instantaneous plant load and ambient conditions. This strategy can result in plant-energy savings of up 12 per cent.

PULLOUT

Energy management consultants, technical service providers, plant owners, plant managers.

VARIABLE HEAD-PRESSURE CONTROL AND VARIABLE INTER-STAGE PRESSURE CONTROL

PLANT ENERGY SAVINGS OF UP TO

12%

PRINCIPLES Variable head pressure control and variable inter-stage pressure control (VIPC) are strategies which aim to improve a plant’s energy efficiency by optimising both the head pressure and the intermediate stage (inter-stage) pressure of the refrigeration plant, based on instantaneous plant load and ambient conditions.

Variable head pressure control The head pressure of a refrigeration plant is the discharge pressure of the high-stage compressors, and is slightly higher or equal to the pressure at which the refrigerant condenses. In a conventional plant, head pressure is fixed and the plant control system attempts to maintain that fixed value. If the head pressure set-point is too low for a given ambient temperature and plant load condition, the condensers will reach capacity and the head pressure will fluctuate with load, potentially causing temperature fluctuations in the plant. If the head pressure set-point is too high, there is an increase in compressor power consumption.

OVERVIEW • Principles: plant head pressure or inter-stage pressure set-points are varied according to ambient condition and plant load, instead of fixed at specific values. • Benefits: reduces plant energy consumption and stabilises plant pressures. • Savings: typical plant energy savings can be up to 12%, with a possible payback period of less than one year. • Implementation: involves changes to the plant control logic for systems fitted with condenser fan variable speed drives (VSDs).

Variable head pressure control aims to optimise the head pressure of a refrigeration plant at any given time while taking into account operational factors such as minimum compression ratios and oil separation as well as variables such as ambient conditions and plant load. When head pressure is optimised, the combined power consumption of the high-stage compressor and the condenser fan is minimised.

September 2017 | www.airah.org.au/nation | HVAC&R Nation | 15

1200

1000

800

600

400

200

0 12am

12pm

12am

12pm

12am

Plant head pressure

12pm

12am

12pm

12am

12pm

• for fixed head pressure 35°C – 30% to 35% of high-stage compressor power consumption. Ambient wet-bulb temperature (°C)

Head pressure (KPA)

HVAC&R Skills Workshop

0 12am

Ambient wet-bulb temperature

Figure 1: Typical plant head pressure under a variable head pressure control (VHPC) logic.

The evaporative condensers are designed to cope with the worst possible conditions in terms of plant load and wet bulb temperatures of ambient air. Therefore, for the greater part of the year, the plant condensers are subject to lower plant loads and wet bulb temperatures. This means, for most of the year, the condensers are oversized for the immediate task, and condensing pressures can, in turn, be reduced to lower power consumption. Furthermore, ambient wet bulb temperature is generally stable for long periods of the day and tends to fluctuate only with a change of weather. As variable head-pressure control (VHPC) depends on wet bulb temperature and plant load, a welldefined VHPC logic would minimise head-pressure fluctuations. Head pressure on an otherwise conventional set-up tends to fluctuate with plant load. Therefore, VHPC, in addition to reducing head pressure when possible, also stabilises the head pressure of the plant, resulting in more efficient and steadier plant operation over the year.

FACT BOX Plant head pressure is often deliberately raised to facilitate hot gas evaporator defrosts. This approach is inherently inefficient as overall performance of the plant is penalised to facilitate a relatively infrequent and minor function. In a VHPC logic, the hot gas defrost is accommodated by allowing a minimum plant head pressure during the defrost period and switching to VHPC mode during other periods. By doing so, the plant is able to obtain the benefits of VHPC logic while still achieving a proper hot gas defrost.

Variable inter-stage pressure control As with head pressure, the inter-stage pressure of a plant can also affect the plant’s energy consumption. The inter-stage pressure of a refrigerant plant is the intermediate pressure between the low-stage and high-stage compressors. The optimal inter-stage

pressure will vary according to plant load and head pressure. Variable inter-stage pressure control aims to optimise the inter-stage pressure in step with variations in head pressure. On a plant where the head pressure is variable, the inter-stage pressure should also be varied to optimise the balance between low-stage and high-stage power consumption.

FACT BOX Variable inter-stage pressure control is only possible where plant inter-stage temperature can be varied. If the interstage vessel is used to provide refrigeration to other plant applications, such as cool rooms or glycol or water chilling, then the inter-stage pressure may have to be maintained at a fixed value or varied only within a narrow range.

PLANT BENEFITS Well-defined variable head pressure control and VIPC can:

The achievable savings also depend on the application, capacities of the heat rejection equipment and oil separators.

Variable inter-stage pressure control Compared to a two-stage system with fixed interstage pressure, VIPC can generate annual energy savings of about 2%. See Appendix B for full details.

IMPLEMENTATION Information requirements For head pressure control you need to know the: • number of compressors • type of compressor – screw or reciprocating • make and model of each compressor • number of condensers • type of condenser – air cooled, water cooled or evaporative • age of the condenser – to allow for sufficient condenser de-rating on a plant with old condensers. For inter-stage pressure control you need to know the: • current plant operating suction, inter-stage and discharge pressures • plant load status.

Equipment requirements You will need: • an ambient dry bulb temperature and relative humidity sensor • discharge and inter-stage pressure transmitters • for screw compressors: slide valve potentiometers connected to the main plant controller • for reciprocating compressors: capacity control solenoids connected to the main plant controller • variable speed drive (VSD) for each condenser fan • sufficient control system hardware and software capability to define the logic.

FACT BOX

• increase system efficiency and capacity • prolong compressor life • enable steadier and more reliable plant operation by stabilising head pressure • optimise plant pressures to reduce the overall plant consumption.

ACHIEVABLE SAVINGS Variable head pressure control Compared to a system with fixed head pressure settings, VHPC can generate annual energy savings of: • for fixed head pressure 25°C – 9% to 12% of high-stage compressor power consumption • for fixed head pressure 30°C – 20% to 25% of high-stage compressor power consumption

16 | HVAC&R Nation | www.airah.org.au/nation | September 2017

For best results, the variable plant pressure control logic should be optimised over the full range of the plant operating conditions. Generally, this requires observation of the plant under a range of load and climatic conditions, and the fine tuning of various parameters.

ESTIMATED FINANCIAL RETURNS Variable head pressure control The capital costs of implementing variable head pressure control depend on: • number and size of VSDs required; this depends on the number of condensers or cooling towers in the plant and their respective fan motor sizes

HVAC&R Skills Workshop • location of VSDs relative to the fan motors; if the distance is great for practical reasons, capital costs would increase due to the need for greater quantities of shielded cabling.

CASE STUDY – McCain Foods McCain Foods, Lisarow, implemented VHPC logic for their refrigeration system and reduced their plant energy costs by 13%, saving an estimated $49,000 a year.

The following parameters have been used to estimate energy savings: Parameter

McCain Foods energy savings and payback

Value

Type of application

Cold store only

High-stage refrigeration load

1000 kilowatts (kW)

High-stage absorbed power (–10°C SST; 35°C SCT)

250 kW 35°C

Design ambient wet bulb temperature

24°C

Number of evaporative condensers

Fan motor capacity per condenser

15 kW

Other cost savings (e.g. maintenance) ($p.a.)

Total cost savings ($p.a.)

Capital cost ($)

Payback period (years)

GHG savings (tonnes CO2 p.a.)

ESCs (number of certificates)

320

49,000

87,000

22,000

0.5

307

339

McCain Foods, Lisarow, has operated several food production and processing lines for the past 40 years including bakery, fruit processing and frozen food production. The annual site electricity consumption is about 13 gigawatt hours, where over 50% is due to the refrigeration systems. The refrigeration plant (see figure 3) consists of a single-stage ammonia system with three screw compressors and two evaporative condensers with their fans speed controlled by variable speed drives (VSD). Cooling is used to chill glycol via two ammonia/glycol plate heat exchangers (PHEs). Before the upgrade, the head pressure set-point of the system was fixed which meant the plant could only operate efficiently at maximum load. On weekends, the load was reduced but energy was wasted by maintaining a high pressure.

$0.15 per kilowatt hours (kWh)

Average power cost

Since the condenser fans were already fitted with VSDs, the project required only the installation of an ambient dry bulb temperature and relative humidity sensor, and the implementation of the VHPC logic on the plant programmable logic controller (PLC) system.

SST = saturated suction temperature; SCT = saturated condensing temperature

PULLOUT

Energy cost savings ($p.a.)

MWh = megawatt hours; p.a. = per annum; CO2 = carbon dioxide

Design condensing temperature

Table 1: Parameters used to estimate energy savings – variable head pressure control.

Item

Estimated costs

Equipment

$10,000 – $25,000

Labour

$5,000 – $15,000

Engineering

$8,000

Programming

$6,000

Total

Electricity savings (MWh p.a.)

The project had an impressive return on investment: it resulted in approximately 320 megawatt hours of annual electricity savings, equivalent to a $49,000 cost saving, at an investment of less than $22,000. No major changes to the equipment were necessary. Consequently, the refrigeration plant did not need to shut down for a significant period of time.

Compressor 1 Condenser 1

Condenser 2

Compressor 2

$29,000 – $54,000

Compressor 3

Table 2: Costs used to estimate energy savings – variable head pressure control.

Liquid receiver

SP LC

Variable inter-stage pressure control Generally the costs involved in relation to the implementation of variable inter-stage pressure logic involve engineering and programming costs only, and savings achievable depend on the degree to which inter-stage pressures can be varied on the specific plant.

Suction accumulator DP: SP: LC: PHE:

Glycol PHE

discharge pressor sensor suction pressure sensor liquid level sensor plate heat exchanger

System schematics of the ammonia refrigeration plant at McCain Foods, Lisarow.

MORE INFORMATION

Condensing temperature set-point for fixed head pressure system (°C)

Energy consumption for fixed head pressure (kWh/year)

Energy consumption for variable head pressure (kWh/year)

Energy savings (kWh/year)

Energy cost savings ($/ year)

Project cost ($)

Payback (years)

25°C

1,382,000

1,250,000

132,000

19,800

29,000–54,000

1.5–2.7

30°C

1,584,000

1,250,000

334,000

50,100

29,000–54,000

06–1.1

35°C

1,820,000

1,250,000

570,000

85,500

29,000–54,000

0.3–0.6

trial ur indus i am yo ation guide refriger

This month’s Skills Workshop has been taken from the Office of Environment and Heritage’s Industrial Refrigeration Guide.

Go to www.environment.nsw.gov.au Table 3: Energy savings and payback – variable head pressure control.

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Next month: Guide to model WHS law September 2017 | www.airah.org.au/nation | HVAC&R Nation | 17

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18 | HVAC&R Nation | www.airah.org.au/nation | September 2017

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Cool Tech

HALOS, BUT NO ANGELS This cockpit-style halo will soon be mandatory in 2018.

The move to introduce frontal protection for drivers was reached in 2016. However, the design process coordinated by the Strategy Group has taken more than a year, with the look and performance of the halo requiring extensive tinkering. An aerodynamic windshield was put to the test alongside the halo, but the distortion caused by the windshield’s shape caused Vettel to feel “a little bit dizzy” – not ideal when piloting a racing car at more than 350km/h. The development of both the halo and windshield came as a direct response to incidents where racecourse debris has caused serious head injuries. The most high-profile recent example was the death of driver Jules Bianchi in 2015. But the list of near misses dates to the Hungary Grand Prix in 2009, when Felipe Massa was struck in the head by a flying spring while driving for Ferrari. The Strategy Group say that the halo design is likely to change slightly before the start of the 2018 season, stating that “with the support of the teams, certain features of its design will be further enhanced.”

Formula One will have an interesting new look in season 2018.

After an arduous testing process, the Formula One Strategy Group has announced that a cockpit-style “halo” will be mandatory for season 2018. Designed to protect drivers from flying debris, the slim carbon structure was chosen ahead of an aerodynamic windshield tested by four-time world champion driver Sebastian Vettel.

At this stage, that support seems to be lukewarm, with several drivers already coming out swinging against the new safety addition, including current world champion Lewis Hamilton. Taking to Instagram, Hamilton labelled the halo “the worst-looking mod in Formula One history”. Not surprising in a sport that has always strived to find a balance between speed, safety, and style. n

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www.lorient.com.au September 2017 | www.airah.org.au/nation | HVAC&R Nation | 19

Cover Feature

HVAC&R organisations with greater diversity perform better.

LEVELLING THE

PLAYING FIELD Numerous s tudies have shown that can lead to diversity in th a more succ e workplace e s s fu l b HVAC&R ind usiness. Alth ustry is a gre ough the Au at example stralian we lag behin o f c u lt u ra l diversity at w d others wh en it comes ork, But as Sean to gender dive McGowan rsity. reports, this is changing too. Ask yourself how many women you know that work in the HVAC&R industry. Chances are you will know a few – probably in non-technical roles within your organisation, such as administration, marketing, human resources … upper management perhaps.

Now ask yourself how many of those women are working in a technical role? Whether you know of one, a couple, or none at all, the reality is that women have been under-

20 | HVAC&R Nation | www.airah.org.au/nation | September 2017

The reality is that women have been under-represented in the HVAC&R industry for many years

represented in the HVAC&R industry for many years, and this continues today. Even with the business case for gender diversity clear for at least a decade, the industry has been slow to encourage women to enter it. But change is occurring. “There is a strong recognition in the engineering sector that it needs to utilise the talents of women who make up half the population, and that by embracing women the performance of the sector and organisations in the sector is dramatically improved,” says Jenny Bailey, leadership coach and author of Women in Hard Hats. She says that by electing to only choose men to work in an organisation, the talent pool is immediately reduced to half – and is reduced even further when it comes to recruiting university graduates (women make up more than half of all university graduates).

Cover Feature n Jenny Smith, Affil.AIRAH

Fridgies are the original

Owner

Jack and Jill of the trades

About Airconditioning, Darwin

And she is buoyed by the introduction of groups like the Women of AIRAH, of which she is the Northern Territory’s chapter representative. “TAFE can be a very isolating space for a woman; however, this can keep you focused on your studies and fast-tracked by your teachers. The introduction of the Women of AIRAH group is addressing this, as well as changes in attitudes in the HVAC&R industry, employers and access to more women in aligned trades. “Attitudes are shifting, and we are learning that gender balance in our workforce is vital to business performance and growth as we become more competitive.” n Jenny Bailey, author of Women in Hard Hats.

THE WOMEN OF AIRAH Groups such as the Women of AIRAH promote innovation through diversity, and provide support for women to increase their participation in both the Institute, and the wider HVAC&R industry. “Being a female in a male-dominated environment can be exhausting and lonely,” says Bailey. “Groups like Women of AIRAH provide social support and the professional development necessary to navigate what is still an uneven playing field for women.” While you might not know of too many women in technical roles, HVAC&R Nation reached out to Lauren Stacey, Jenny Smith, Ezra Finch and Sophie Decottignies to find out what life on the tools is really like for a woman. And their response might surprise you.

After completing her apprenticeship, Smith was asked to run the first ever pilot course for women in trades – leading to her completing a Diploma in Education. She also spent a great deal of time teaching Indigenous Australians. But even as engineering undergoes a gender shift, she says the gender imbalance in HVAC&R trades remains evident today. “I feel that men are chosen over women in the trades,” Smith says. “As to why, I’m not sure but even now when I show up at a customer’s home to do a job, the customer is still amazed. “There are not many female refrigeration and air conditioning tradeswomen out there – perhaps because women don’t see the career path as attractive, or see it as less flexible.” For this reason, Smith says trade opportunities should be presented to schools and young women encouraged to seek and discuss HVAC&R pathways and opportunities.

EN OF AI R M

“I spent my spare time making freezer boxes and contraptions from scratch,” she says. “This attitude was the thing that challenged the perception of me, as a woman, being in a totally male-dominated industry. So whether they were supportive or not of me being there initially, they came around when they saw my enthusiasm and motivation to learn.”

“It is essential to find an employer sensitive to the needs of women, so that female fridge mechanics feel like they are working in a supportive environment, and that they are not forced to act like men just to fit in.”

Living and breathing the profession as an apprentice, Smith drove her tradesmen crazy “wanting to know everything.” Her enthusiasm also garnered the support of her TAFE lecturers and parents.

INN

However, Bailey says there are obvious obstacles to the industry improving its gender diversity in technical roles.

“Fridgies are the original Jack and Jill of the trades,” Smith says.

“It is a growing industry, providing practical work that contributes to the wellbeing of the community,” she says. “It is also work that is difficult to offshore, making it more future-proof.”

INNOVATION THROUGH DIVERSITY

Having worked as an engineer and as a senior executive for some of world’s biggest companies, including KPMG, Rio Tinto, SKM and Yarra Valley Water, Bailey believes that the HVAC&R industry can be attractive to women.

After working with many knowledgeable and talented people over that time, Smith was inspired to create customised solutions for clients, products and environments. As well as project management, scheduling and facilities management, she still manages to find time to work on the tools.

WOMEN OF AIRAH

Research has also shown that organisations with a greater diversity simply perform better. Greater diversity in the workplace increases the range of perspectives and ideas available, promotes a more “fair and equitable” workplace and reduces staff turnover.

Jenny Smith has worked in the HVAC&R industry for over 35 years, and currently operates About Airconditioning in Darwin.

W O

“It is like picking the Australian cricket team from only Victoria, Queensland and South Australia,” Bailey says.

THROUGH

Join AIRAH for the inaugural launch event for the Women of AIRAH (WOA) The WOA group will develop AIRAH’s strategy for supporting women and increasing their participation in both AIRAH and the HVAC&R industry. They will work with local AIRAH divisions to run events, networking sessions and other initiatives. At this event in Sydney, inspirational speakers from leading Australian HVAC&R, property and consulting companies share their stories about how diversity has given their organisations a competitive edge in the marketplace. Date:

September 12

Time:

6pm

Venue: Doltone House, Darling Island Wharf Pyrmont Point NSW

www.airah.org.au/events

September 2017 | www.airah.org.au/nation | HVAC&R Nation | 21

Cover Feature n Ezra Finch Refrigeration and air conditioning mechanic Building & Asset Services, Department of Housing and Public Works Queensland

“My employer has been very supportive,” she says. “I’ve had several mentors across my time to guide and teach me, and ensuring I knew how to complete tasks using various approaches.”

Stacey believes there is a growing trend toward women entering a trade, and notes that many more companies are becoming “equal-opportunity employers”.

Finch believes opportunities exist for women seeking a technical role in the industry, but says that determination is vital.

“I have had both positive and negative feedback across my time, but the negative feedback has come more from surprise, as it’s not common to see women in the trade,” Stacey says.

“You just have to be up for the challenge,” she says. “Don’t give up. It took me 12 years to secure my apprenticeship – I just never gave up applying for the positions.” n

“But in saying that, I have had so much positive feedback from clients to suppliers through to my TAFE lecturers, who have been more than willing to teach me and treat me the same as anyone else.” n

n Lauren Stacey

n Sophie Decottignies

Third-year apprentice

Energy services contract administrator

BioCool Refrigeration

Veolia Australia and New Zealand Sophie Decottignies has worked in the air conditioning and refrigeration industry for 27 years – firstly in her native France, and later in Perth after migrating to Australia on a skilled work visa. But two years ago, after being injured at work, she was forced to leave her role as a field technician and take up an office position.

Ezra Finch’s entry into the HVAC&R industry came as a mature-aged apprentice.

“I really loved my job, mainly because of its diversity – it was never boring and you are always challenged with new things,” Decottignies says.

Choosing woodshop and metal shop classes over home economics at high school, she subsequently completed a Certificate in Engineering and Manufacturing, which became a pathway to her chosen field.

Decottignies was attracted to the industry after hearing about the career of her cousin, a fridgie in the French army. She began her studies at age 16, and was the first and only girl to apply for the diploma at the time.

“I loved working with tools – creating and fixing things and problem-solving,” Finch says.

Don’t give up. It took me 12 years to secure my apprenticeship – I just never gave up applying for the positions

Gaining an apprenticeship led to her now working as a refrigeration and air conditioning mechanic for Building & Asset Services under the Department of Housing and Public Works for the Queensland government. She says she mainly services and maintains government sites in Brisbane, and works on commercial central air conditioning plant, air-handling units, cooling towers, motors, pumps and exhaust systems. “The job is always changing – never repetitive – and I am always being exposed to different challenges and learning something new every day,” Finch says. Like others, Finch has encountered challenges along the way, but has addressed them like any other – with patience and determination. She says in-house training has been valuable in learning different building management systems (BMS), commissioning and calibrating sensors and following site-specific processes and procedures.

Lauren Stacey is a third-year apprentice with BioCool Refrigeration in Perth – a business she runs alongside her husband, who is also a refrigeration mechanic. Winner of the First Year Award as the Most Deserving Apprentice at the annual Western Australian AMCA Industry Awards, Lauren’s entry into the industry is somewhat unique – but the challenges of learning the trade remain. “It actually started as a bit of a joke, when my husband’s work load increased and he was discussing putting on an apprentice or sub-contracting work out to another tradesperson,” Stacey says. “I said I would become his apprentice and it just snowballed from there!” Stacey says she has been fortunate to work on a variety of different systems and equipment, which has given her confidence and allowed her skillset to grow. “I must say I think I have an advantage,” she says. “I have had my own tradie available all day to answer my questions and show me how things work. He has been able to take extra time, and I have had the opportunity to try new things without the time constraints of some businesses.” Stacey loves the variety of her work, and the constant challenges available in the industry.

“One of the teachers told me that one of the reasons they accepted my application was to see whether a girl could do the job,” she says. “I took that as a challenge and ended up becoming passionate about it.” Soon after, she gained her first job working on commercial refrigeration and air conditioning systems operating on ammonia, CO2 and HCFCs, as well as cooling towers, air compressors, and other systems. “My first employer chose me because his son was a ballet dancer,” Decottignies says. “He thought it was only fair to also give me a chance to work in the male world.” Although many employers were supportive and encouraging of Decottignies’ place in the industry, just as many challenged her position. “When I was 26 years old, I wanted the same status as the other fridgie in my team,” she says. “However, I was told by my by senior management that they couldn’t, as I was too young and a woman – even though I was doing the same work as the men. It was a year later that they finally gave me the same status.” Today, Decottignies works as a contracts administrator for energy company Veolia, where she combines her knowledge as a technician and administrator. She says despite opportunities being out there for women in the trade, they are often dependent on how the employer or management view women and their capabilities.

“On a day-to-day basis, your jobs are often varied, and this keeps things fresh and interesting.”

“Even though I believe gender-related issues are slowly decreasing, there is still a lot of work to do – particularly at a young age in the education system – to further reduce the problem,” Decottignies says.

As well as being an administrator of the Refrigeration Workers of Western Australia Facebook page, which connects 2,000 like-minded people, recently she has been introduced to the Women of AIRAH group.

“But a career in HVAC&R can be very rich, stimulating and challenging, and open a lot of opportunities due to its diversity. So go for it and be prepared to be successful!” n

22 | HVAC&R Nation | www.airah.org.au/nation | September 2017

Green wedge

ALL ABOARD THE SOLAR EXPRESS! The new diesel electric multiple-unit rolls in.

The project is part of a strategy devised by Indian Railways to reduce the carbon footprint of its diesel-reliant train network – a plan that involves the design and construction of five 1,000MW solar plants over the next five years. The strategy also makes use of bio fuels and wind energy, as well as installing bio-toilets, and recycling water.

The DEMU’s PV panels soak up the Indian sunshine during transit. The energy generated is stored in 120Ah battery packs, which lessens the strain from the diesel component of the DEMU’s India’s green revolution remains on track. powertrain. The electrical needs of the train – such A new diesel electric multiple-unit (DEMU) train has as lighting, door operation, passenger information, and so on – all make use of the power generated officially entered service in India. Pulling six carriages, via the PV panels. the DEMU is topped with photovoltaic (PV) panels to meet the needs of the train’s electrical systems with clean energy.

Each carriage is fitted with 16 PV panels rated at 300W, with the system having the potential to develop

up to 20kWh of energy per day. Storing unused energy in the battery banks means the train’s electrical systems can operate at night without diesel intervention. Estimates from Indian Railways have spruiked that the PV panels save around 21,000 litres of diesel per year, while reducing the carbon signature of each coach by 9 tonnes per annum. And it’s full steam ahead for the local Ministry for Railways, which says 24 more train carriages are scheduled to be fitted with PV panels before the end of the year. n

September 2017 | www.airah.org.au/nation | HVAC&R Nation | 23

Around the nation 1

SKILLS TO THRILL THE WORLD

Nathan McHugh, a young refrigeration and air conditioning technician from Jimboomba in south-eastern Queensland, has been selected by WorldSkills Australia to compete in the 44th World Skills International in Abu Dhabi next month. McHugh, 21, formerly a student at TAFE Qld SkillsTech, works for DTM Air Services. To qualify for WorldSkills, he competed – and triumphed – against refrigeration competitors from Russia, China, Hong Kong, Malaysia and Brazil in a four-day Global Skills Challenge held in China in April. The challenge saw more than 100 participants from 16 countries test their skills in 21 trades. McHugh and his teammates, known as the Skillaroos, are elite young Australian tradespeople. They now have the opportunity to compete against their international counterparts. McHugh has been training towards possible selection to Abu Dhabi since May last year when he won the Gold Medal at Australia’s Refrigeration and Air Conditioning National WorldSkills competition held as part of the 2016 ARBS Exhibition in Melbourne. As part of his reward for winning the national competition, in October last year he attended the Chillventa International HVAC&R Exhibition in Nuremberg, Germany. Sponsorship from LuVe Contardo Pacific helped him attend. Not only did McHugh see and learn about the latest developments and technologies at Chillventa, he also observed the German refrigeration mechanics compete in their national WorldSkills competition held during the exhibition. He has worked closely with his mentor and WorldSkills Australia’s International Judge, Carl Balke, as well as Balke’s fellow teachers at TAFE Qld SkillsTech in Brisbane. WorldSkills Australia’s previous International Judges, Chris MacDonald from City Holdings and Noel Munkman from ARC, also lent a hand.

Aged 19 to 22, the Skillaroos include the trade and skills of bricklaying, patisserie and confectionery, heavy vehicle mechanics, hairdressing, landscape gardening, refrigeration and air conditioning, carpentry, and wall and floor tiling. Held from October 14–19, the 44th WorldSkills International Competition will see more than 3,000 participants, including competitors, experts and officials from 77 countries compete in 51 skills. Ranked 12th in the world, Australia is aiming to finish in the top 10 this year n

VICTORIA’S CHEAP LABOUR

The latest Tradie Price report from ServiceSeeeking. com shows Victoria still has the cheapest tradies. The quarterly data reveals the average cost of a Victorian tradie sits at just $55.90 per hour, a massive 8.5 per cent below the national average. In Australia, the home renovations market employs around one million people, and contributes a colossal $99 billion to the economy. Although renovation activity is up in Victoria, a competitive environment is keeping tradie prices down. Plumbers take the prize as the most expensive tradie in Victoria, charging on average $76.20 per hour, up 4.9 per cent on last quarter. Electricians take out second place across the state, with an average hourly rate of $72.30. Carpenters ($59.30) are the ones to watch this year, recording a quarterly increase of 13.2 per cent. Painters are the cheapest tradie in the state, at just $38.80 per hour, after experiencing a year-on-year drop of 19.7 per cent. “Now is the time to get jobs done in Victoria,” says ServiceSeeking.com.au CEO Jeremy Levitt. “Renovators need to take full advantage of these low prices, and get any outstanding work done.” n

24 | HVAC&R Nation | www.airah.org.au/nation | September 2017

KEVIN’S HIGH STANDARDS

HVAC&R industry veteran Kevin Lee, F.AIRAH, has earned a Standards Award. The Standards Awards are presented to those who have made significant contributions to standardisation and demonstrated outstanding service in enabling Standards Australia to attain its objectives. Through their exceptional work in developing Australian and international standards, the award winners have helped benefit Australia. Lee has an extensive background in the refrigeration and air conditioning industry, specifically in product design, manufacturing and regulatory compliance. A former director and chair of the Refrigeration and Air Conditioning Industry Board, he’s a long-time member of AIRAH. Lee has over 20 years’ experience on Standards Australia committees and ISO international committees, including a role as Chair of the committee ME-006, Refrigeration Safety. Notable achievements include the development of the AS/NZS 1677 series on refrigeration safety, and the recent Australian adoption of international standards to supersede this series. n

SEELEY’S BORDER MANOEUVRE

Seeley International has announced plans to relocate its Albury manufacturing plant to a larger $20m purpose-built facility to be constructed at nearby Wodonga. The move is to be part-funded by a grant from the Victorian Premier’s Job and Investment Fund, in a bid to establish a state-of-the-art manufacturing hub that will produce a range of innovative products to be sold in Australian and international markets. “As a long-standing employer within the AlburyWodonga community, Seeley International is pleased that this investment accommodates our expansion

Around the nation 5

needs and positions the company for significant jobs growth and success in the years ahead – with 64 per cent forecast growth in new local employment opportunities expected to be created in the next five years,” says Frank Seeley, Affil.AIRAH, the company’s founder and executive chairman. In acknowledging the grant contribution of the Victorian government, Seeley says it was critical that all levels of government assist manufacturers to develop new products, and support expansion of production facilities. Go to www.seeleyinternational.com n

CROWN JEWEL OF CROWN GROUP

A state-of-the-art rooftop “Sky” cinema is set to be the pinnacle of a collection of resort-style facilities at Waterfall by Crown Group. The latest project from Sydney-based property developer Crown Group allows residents to enjoy their favourite films while experiencing panoramic views and natural surrounds under the stars. Waterfall by Crown Group will also offer residents a tranquil recreational deck, an Infinity rooftop pool, a secluded bamboo-covered walkway, a state of-theart cantilevered gym, function room with a catering kitchen, music room, and onsite retail.

Late last month the VBA introduced VBA360, an online self-service portal for Licensed Plumbing Practitioners to purchase and manage Compliance Certificates, including drain bookings and cancellations. From this date, the price of Compliance Certificates has reduced to $33.50. Mechanical service is one of the main classes of plumbing work, and refrigerated air conditioning is a specialist class of work under Victoria’s Plumbing Regulations 2008 definitions. Practitioners will also be able to register for a VBA360 account by visiting www.vba.vic.gov.au. Changes to the management and purchasing of Compliance Certificates have been introduced. These should provide more online self-service options, introducing greater flexibility to Licensed Practitioners and reliable and improved technology.

SYDNEY TRADE NIGHT SUCCESS

AIRAH Trade Nights are a great opportunity to broaden your networks and see the HVAC&R industry's latest innovations. The latest Sydney Trade Night was no exception. Hosted at the iconic Lunda Park, more than 260 attendees were there to check out the latest technology in the HVAC&R industry from 78 exhibitors.

Construction is scheduled for completion in 2020. n

Positive feedback was received from both attendees and other industry professionals.

VBA REVAMPS LICENCE SYSTEM

The Victorian Building Authority (VBA) is switching to a single, integrated system designed to deliver a more streamlined and effective regulatory service for consumers, practitioners and staff.

Testo has a new brand element: “Be sure”. Testo says the slogan encompasses the idea that the company wants to provide innovative solutions in the form of accurate, portable testing instruments. “When it comes to serving food, storing pharmaceuticals or maintaining appliances, you can never be too careful. You need to be sure,” the company says. “It's the idea that drives Testo’s tools and services: the need for absolute certainty. In the age of boundless information, don't you think you should always be sure? “Dependable servicing gives you the peace of mind that experienced professionals have ensured your tools meet all the criteria to stay as reliable as the day you bought them,” Testo says.

Go to www.testo.com n

“The meaning of luxury is reflected in all aspects of this stunning project,” says project director Prisca Edwards. “Waterfall by Crown Group provides incredible facilities and residents’ spaces in an ideal location in Sydney.”

BE SURE WITH TESTO

“The world is changing quickly and those who adapt are best prepared for the future; don't you think your tools should provide innovative solutions?”

Go to www.vba.vic.gov.au n

CAREL’S POLISH ACQUISITION

Continuing its international expansion strategy, the Carel Group has fully acquired Alfaco Polska, based in Wrocław, Poland. Carel’s Polish distributor for more than 20 years, Alfaco posted sales of about €11 million last year, up around 18 per cent over 2015.

“The Sydney Trade Night had a real buzz about it this year,” says HVAC&R Nation advertising executive John McGrath. “It was great to catch up with those in the Australian HVAC&R community, and to see everyone getting so much out of the night.”

“Alfaco is a very important long-term partner for us in Poland,” says Carel Group MD Francesco Nalini. “With this acquisition, we are continuing our strategy to establish a direct presence in all major international markets, meaning we can be close to our customers and support them in terms of technology, logistics and service.”

Go to www.airah.org.au/tradenights n

Go to www.carel.com n September 2017 | www.airah.org.au/nation | HVAC&R Nation | 25

AIRAH News

IT’S AN HONOUR FOR SA APPRENTICES

The 2017 SA Award winners pose for pictures with AIRAH National Member manager Bettina May.

The pride of South Australia – its on-the-rise fridgies, of course – were recently recognised at a special cocktail event. AIRAH recently celebrated achievements of HVAC&R industry apprentices at the 2017 AIRAH SA Apprenticeship Awards Night. Hosted last month at the Hackney Hotel in South Australia, 60 of the best up-and-coming apprentices were honoured for their achievements in the HVAC&R industry over the past year. “The Apprentice Awards Night is a fantastic way for the South Australian HVAC&R industry to recognise

outstanding candidates newly entering the field,” says AIRAH’s SA division committee president Ben Quast M.AIRAH, MC for the evening. “It provides a valuable opportunity for attending apprentices to engage with the wider industry in which they are just beginning to become a part of.” The night’s highest honour went to Patrick Page, who nabbed the Apprentice of the Year Award. Runner-up Apprentice of the Year Award went to Benjamin Strapp, Affil.AIRAH. Nathan Budarick, Stud.AIRAH, took home the Encouragement Award, and Tyson Satala, Stud.AIRAH, earned the Airefrig Scholarship Award. “All candidates nominated were selected due to their outstanding academic performance during their time completing TAFE qualifications,” Quast says. “But it’s those with a sincere passion and enthusiasm for the industry who stand out.” n

Thanks to our sponsor The evening was made possible by event sponsor n ActronAir

From left Runner-up Apprentice of the Year Award Benjamin Strapp, Affil.AIRAH, and Encouragement Award winner Nathan Budarick, Stud.AIRAH pose with Bettina May and Ben Quast, Affil.AIRAH. 26 | HVAC&R Nation | www.airah.org.au/nation | September 2017

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September 2017 | www.airah.org.au/nation | HVAC&R Nation | 27

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AIRAH’s HVAC Hygiene Best Practice Guidelines is available to purchase in hard copy. n Establishes the criteria for evaluating the internal cleanliness of HVAC system components n Clearly determines when cleaning is required, according to the building use n Describes the components of HVAC systems to be evaluated n Describes the types of contamination likely to be encountered and includes for post fire and flood damage assessments

n Specifies minimum inspection frequencies for various HVAC systems and components for scheduled maintenance programs

Purchase online at www.airah.org.au/store 28 | HVAC&R Nation | www.airah.org.au/nation | September 2017

AIRAH and Industry classifieds Ballarat Trade Night

EVENTS Women of AIRAH: Innovation Through Diversity Forward-thinking business leaders recognise the importance of diversity in the workplace. Our inspirational speakers from leading Australian HVAC&R, property and consulting companies share their stories about how diversity has given their organisations a competitive edge in the marketplace. Date: Tuesday, September 12 Time: 6pm Venue: Doltone House, Darling Island Wharf The Parkview 48 Pirrama Road Pyrmont Point, NSW

The Future of HVAC 2017 Conference

AIRAH Trade Nights are a great opportunity to broaden your networks and see the HVAC&R industry's latest innovations. Date: Thursday, September 14 Venue: The Mercure Hotel Ballarat, Vic Cost: Free

Tasmanian President’s Dinner The AIRAH Tasmanian division President and committee invite you to join them for the 2017 Tasmanian President’s Dinner. Date: Thursday, September 21 Venue: Rydges Federation Room 393 Argyle Street North Hobart, Tas Cost: $70 for AIRAH members; $95 non-members

Canberra Trade Night

Now in its fifth year, the Future of HVAC Conference has become the must-attend conference of the year. Industry leaders will explore the advances, ideas, and innovations that are driving our industry’s future. Date: Wednesday, September 13 Venue: Doltone House, Darling Island Wharf 48 Pirrama Road Pyrmont Sydney, NSW

FREE Classified Ads

AIRAH Trade Nights are a great opportunity to broaden your networks and see the HVAC&R industry's latest innovations. Date: Thursday, September 28 Venue: Exhibition Park, Parkes Room Canberra, ACT Cost: Free

Women of AIRAH: Women in Engineering

TRAINING

Join the Women of AIRAH Victorian division committee and Jenny Bailey, author of Women in Hard Hats, in a discussion on building leadership, confidence, and life satisfaction in the engineering sector. Date: Monday, October 16 Venue: Rendezvous Hotel, Heritage Lounge 328 Flinders Street Melbourne, Vic Cost: Free for members, $25 for non-members

Vic – S moke control & Fire Dampers

This one-day course outlines how AS/NZS 1668.1 applies the principles of smoke control in multi-compartment buildings. Why is smoke control required in buildings? What are the hazards generated by smoke and how does smoke move? Date: Monday, September 21 Time: 9am – 5pm Venue: Rydges on Swanston 701 Swanston Street Melbourne, Vic

AIRAH Awards Night

NT – C FD Analysis of HVAC Plant

The AIRAH Awards will return in 2017 to honour those who have delivered significant contributions to our industry. Open to individuals, companies, corporate bodies, institutions and government authorities, the 2017 Awards will recognise work carried out during 2015/2016. Date: Thursday, November 2 Venue: Piers 19–21, Level 3 26–32 Pirrama Road Jones Bay Wharf Pyrmont, NSW

HVAC&R Nation is offering a free industry classified service!

Join AIRAH for a session on CFD Analysis (computational fluid dynamics) of HVAC plant, presented by Con Liascos from Daikin Australia, an AIRAH company member. Date: Thursday, September 28 Time: 5.30pm Venue: TBC Cost: Free for members, $55 for non-members

Send in your submissions, text only – no images or logos.

Send your submissions to: brihony.tulloch@airah.org.au or c/o AIRAH, Level 3, 1 Elizabeth Street, Melbourne Vic 3000.

Whether you are looking, selling, trading or tendering – HVAC&R Nation classifieds is the best way to spread the word!

SAFETY FIRST

FLAMMABLE REFRIGERANTS Safety Guide

SAFETY

GUIDE

SAFETY

FLAM

MABL E REFRI GERA NTS HEATING E OF INST ITUT ONI NG AND DITI TRA LIAN , AIR CON THE AUS Enclosed RAT ION vehicles includ REFRIGE e:

SAFETY

GUIDE

FLAMMA BLE

Enclosed vehicles

REFRIGE RANTS

CONSIDER

include:

cylinders in a

vehicle that is

an enclosed

transport is to be used to Is the vehicle that an enclosed vehicle? open to the gas cylinder(s) the vehicle is not as: luggage area of such vehicles That is to say the air) and includes the elements (open

over the tray

vehicle

without windows) • A van (with or • A panel van ge • A station wagon the tray or luggage/stora a canopy over • A utility with area over the tray a torneau cover ge • A utility with the luggage/stora vehicle whereby • Other type of part of the inside of the vehicle is compartment

Utility with a canopy

transported, less

Enclosed trailer This self-assess of all gas cylinders water capacity Is the gas cylinders ment document is for the transport 250L? up to a quantity than Flammab

vehicle is deemed are down, the an enclosed vehicle

of of 250L of le gases in Division 2.1 enclosedcabinet(s) wagons, and in a vehicles such shouldstored as cylinders be Section the gas Are 12 of this guide. read in conjunction vans and with the the vehicle? inside For quantities greater than gases, the 250L of Division full the Transport requirements of thegas escape2.1 Flammable any Australian Code ofsealed Dangerou whereby (ADG s Goods by vehicle? for apply and Is the7)cabinet of the enclosed Road reference forcannot enter the inside requireme must be made and Rail nts. to the ADG 7 or tube in the Is there a pipe to the outside?

cabinet, which

is vented

NTS

SAFETY

2 dangerous

MANDATO

RY ACTION

GUIDE

goods

ITEM

CONSIDER SATISFAC

Utility with

a cover over

TORY Transport of gas cylinder s in a vehicle Transport that is an of gas cylinder enclosed vehicle in an enclose d vehicle s Yes No Action required

the tray

Is the vehicle that is to be the gas cylinder(s) used an enclosed to transport vehicle? That is to say the elements the luggage area of the vehicle (open air) and includes such is not open to • A van (with vehicles as: or without windows) • A panel van • A station wagon • A utility with a canopy over area the tray or luggage/storage • A utility with a torneau cover • Other type over the tray of vehicle whereby the compartm ent is part of the inside luggage/storage of the vehicle Is the water capacity of than 250L? all gas cylinders transporte d, less

an enclosed vehicle

No Yes When cylinders the covers Transport of gas vehicle are down, the vehicle is deemed in an enclosed Utility with a cover enclosed compartment

E REFRI GERA

Traffic light in a “tool assessment system of trade” for the transp vehicle ort of Class

GUIDE

Y SATISFACTOR

Transport of gas

When the covers

SAFETY

us goods t of Class 2 dangero for the transpor ent system Utility with an enclosed Traffic light assessmvehicle compartm ent ACTION ITEM in a “tool of trade” MANDATORY

REFRIGE RANTS

Utility with an

FLAM MABL

ble Flammearants Refrig FLAMMA BLE

Action required

is YES, to this question If the answer with an open consider a vehiclespace such as a trayUtility with a canopy luggage/storage truck.

the tray a canopy over aids the For vehicles with install a vent that the of the vehicle, which will negate the in circulation of air flammable gases build-up of any the vehicle. storage area of

Are the gas cylinders stored inside the in a cabinet(s) vehicle?

is NO, to this question for a If the answer conditions apply. then the (relaxed) vehicle do not “Tool of Trade”

Is the cabinet cannot enter sealed whereby any gas the inside of the enclosedescape vehicle? Is there a pipe to the outside?or tube in the cabinet,

the door the seal around to a As an example, should be similar The of the cabinet refrigerator. door on a household is held cold air in the refrigerator seal. in by the door

which is vented

If the answer to this question consider a is YES, vehicle with luggage/s torage space an open truck. such as a tray For vehicles of the vehicle,with a canopy over the tray install a vent circulation that aids of build-up of air which will negate the any flammable the storage area of the vehicle. gases in the

If the answer to this question then the (relaxed) is NO, condition “Tool of Trade” vehicle do s for a not apply.

As an example, of the cabinet the seal around the door should be door on a similar to household refrigerato a cold air in r. The the in by the door refrigerator is held seal. The pipe or tube to be discharged allows any leaking gases to outside atmosphe re.

gases allows any leaking The pipe or tube to outside atmosphere. to be discharged

Are there appropriat e markings door of the on the cabinet, to indicate its contents?

Enclosed trailer

markings on the Are there appropriateto indicate its contents? door of the cabinet,

of for the transport nt document is 2.1 This self-assessme a quantity of 250L of Division to such as vans and gas cylinders up in enclosed vehicles the Flammable gases be read in conjunction with wagons, and should guide. 2.1 Flammable Section 12 of this than 250L of Division Code for For quantities greater of the Australian Rail gases, the full requirements Goods by Road and ADG 7 Dangerous the Transport of reference must be made to the and (ADG 7) apply . for requirements

www.ai rah.org

.au www.ai rah.org

.au 67

www.airah .org.au

INDUST

3 DE 201

www.airah .org.au

RY GUI

FREE ONLINE PUBLICATION AIRAH has released its Flammable Refrigerants Safety Guide, which is now available for FREE download. Believed to be the first of its kind in Australia, the guide was developed by independent organisations and stakeholders. AIRAH’s Flammable Refrigerants Safety Guide covers the health and safety risks involved in the design, manufacture, supply, installation, conversion, commissioning, operation, maintenance, decommissioning, dismantling and disposal of HVAC&R equipment and systems that contain a flammable refrigerant.

The guide is available to download FREE from www.airah.org.au Select the “Resources” tab then click “Technical Resources” on the drop-down menu.

September 2017 | www.airah.org.au/nation | HVAC&R Nation | 29

The Lighter Side

This month’s Lighter Side is brought to you by DA19

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Check out more Lighter Side submissions on the AIRAH Facebook page @AIRAHconnect.

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••• 21

g and Heatin

3000 te of urne VIC lian Institu Street, Melbo 8949 th 3 39614 1 Elizabe Fax: +61 Level 3, 3000 3 8623 Tel: +61

Austra

h.org.au www.aira

Brought to you by

1 WINNER

PThisEEK-A-BOO shot of a “possible” condenser was sent in by Shahim in Victoria. n

I TAW A PUDDY TAT IThisTAWT furry helper was spotted by Ben in Victoria. It’s great to see a new generation of fridgies looking to get their claws into the HVAC&R industry. n

PIPE PATCH-UP PRyan ATCHY from Victoria sent in this pic of a patched-up pipe. Think it might be time to order in some new parts.. n

PROPS GWhoIVING needs a concrete slab when you’ve got concrete cinder blocks in the back of the ute? Snapped by Ryan in SA. n

UST BUCKET RSpotted by Shane on a site in Queensland looking a bit worse for wear. Has the old girl still got some life in her yet? n

HAVE YOU COME ACROSS SOMETHING SCARY, UGLY OR JUST PLAIN FUNNY? If your entry is deemed the monthly winner, a bottle of Jim Beam bourbon 750ml will be on its way to your door. Please include a postal address with your entry. Entrants must be aged 18 years or over. Send submissions to Managing Editor, Matthew Dillon at matt@airah.org.au

30 | HVAC&R Nation | www.airah.org.au/nation | September 2017

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